Modular Kaizen

Grace L. Duffy

Description

Modular kaizen is a development of necessity in our rapidly changing world where improvement has to happen “on the fly”. Modular kaizen is the counter point to kaizen blitz, where team members are locked in a room to hammer out a solution to some problem or opportunity. In the hectic, interrupt driven environment of many organizations, it is simply not possible to remove critical players from normal operations for any length of time.
Modular kaizen is an improvement approach that integrates quality techniques into the busy schedule of everyday activities. All of the components of an effective kaizen event are planned; however, the activities are scheduled in small segments, or “modules” that fit the rapidly changing time demands of team members and subject matter experts. This approach is complementary to the Plan-Do-Check-Act (PDCA) and Define, Measure, Analyze, Improve, Control (DMAIC) models of quality improvement.
The author of this book calls upon a 40 year career to incorporate techniques, innovations and lessons learned in the pursuit of effective continuous and breakthrough improvement and use the resources, people, and schedules already in place to get things done.
If you are looking for proven approaches to integrating quality improvement into daily work, this is your book.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Gestion et management
• DMAIC
• Círculo de Deming
• PDCA
• Economics
• Six Sigma
• Roue de Deming
• Management

Informations

• Publié par: ASQ Quality Press
• Date de parution: 04 novembre 2013
• Nombre de lectures: 1
• EAN13: 9781953079770
• Langue: English
• Poids de l'ouvrage: 2 Mo

Extrait

Modular Kaizen
Duffy.indb 1 10/24/13 10:33 AMAlso available from ASQ Quality Press:
The ASQ Quality Improvement Pocket Guide: Basic History, Concepts, Tools, and
Relationships
Grace L. Duffy, editor
Quality Function Deployment and Lean-Six Sigma Applications in Public Health
Grace L. Duffy, John W. Moran, and William J. Riley
The Executive Guide to Improvement and Change
G. Dennis Beecroft, Grace L. Duffy, and John W. Moran
The Public Health Quality Improvement Handbook
Ron Bialek, John W. Moran, and Grace L. Duffy
The Quality Improvement Handbook, Second Edition
ASQ Quality Management Division and John E. Bauer, Grace L. Duffy, Russell T.
Westcott, editors
Office Kaizen: Transforming Office Operations into a Strategic Competitive Advantage
William Lareau
Office Kaizen 2: Harnessing Leadership, Organizations, People, and Tools for Office Excellence
William Lareau
Lean Kaizen: A Simplified Approach to Process Improvements
George Alukal and Anthony Manos
The Quality Toolbox, Second Edition
Nancy R. Tague
Root Cause Analysis: The Core of Problem Solving and Corrective Action
Duke Okes
The Certified Manager of Quality/Organizational Excellence Handbook, Fourth Edition
Russell T. Westcott, editor
Root Cause Analysis: Simplified Tools and Techniques, Second Edition
Bjørn Andersen and Tom Fagerhaug
To request a complimentary catalog of ASQ Quality Press publications, call
800-248-1946, or visit our website at http://www.asq.org/quality-press.
Duffy.indb 2 10/24/13 10:33 AMModular Kaizen
Continuous and Breakthrough
Improvement
Grace L. Duffy
ASQ Quality Press
Milwaukee, Wisconsin
Duffy.indb 3 10/24/13 10:33 AMAmerican Society for Quality, Quality Press, Milwaukee 53203
© 2014 by ASQ
All rights reserved. Published 2013
Printed in the United States of America
19 18 17 16 15 14 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
Duffy, Grace L.
Modular kaizen : continuous and breakthrough improvement / Grace L. Duffy.
pages cm
Includes bibliographical references and index.
ISBN 978-0-87389-864-5 (alk. paper)
1. Total quality management. 2. Quality control. 3. Organizational effectiveness. I. Title.
HD62.17.D84 2014
658.4′013—dc23
2013037784
No part of this book may be reproduced in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the publisher.
Acquisitions Editor: Matt Meinholz
Managing Editor: Paul Daniel O’Mara
Production Administrator: Randall Benson
ASQ Mission: The American Society for Quality advances individual, organizational, and
community excellence worldwide through learning, quality improvement, and knowledge
exchange.
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audio, and software are available at quantity discounts with bulk purchases for business,
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To place orders or to request a free copy of the ASQ Quality Press Publications Catalog, visit our
website at http://www.asq.org/quality-press.
Printed on acid-free paper
Duffy.indb 4 10/24/13 10:33 AMTable of Contents
List of Figures and Tables ix
Preface xiii
Acknowledgments xiv
Part I What Is Modular Kaizen? ................................. 1
Chapter 1 Introduction to Modular Kaizen ............................. 3
Modular Kaizen Supports Both Incremental and Breakthrough
Improvement .................................................... 5
How Modular Kaizen Relates to the Family of Kaizen Approaches ........ 6
The Organization Must Be Viewed as a System ......................... 6
The Birth of Modular Kaizen ......................................... 9
Remove Disruptions to Improve Flow ................................. 11
The Tools of Modular Kaizen 12
Process and Outcome Measures in Modular Kaizen ..................... 13
Application Examples Using Modular Kaizen .......................... 14
Notes ............................................................. 14
Chapter 2 Continuous versus Breakthrough Improvement ............... 15
Introduction ....................................................... 15
General Sequence for Improvement Efforts ............................ 16
Continuous Improvement ........................................... 17
Breakthrough Impr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Innovation: Evolution or Revolution? ................................. 22
Change Management ............................................... 24
Notes ............................................................. 25
Chapter 3 Alignment Using Top- Down and Bottom- Up Measures ......... 27
Introduction 27
How to Align ...................................................... 28
The Balanced Scorecard ............................................. 29
An Alignment Tool: Creating Top- Down Line of Sight ................... 37
Using the Alignment Tables .......................................... 38
Alignment Is a Core Concept within Modular Kaizen 41
Notes 42
v
Duffy.indb 5 10/24/13 10:33 AMvi Table of Contents
Chapter 4 The Organization as a System ............................... 43
Introduction ....................................................... 43
A View of the System as a Whole ..................................... 43
System versus Process ............................................... 45
The System View of Process Improvement ............................. 46
Large-Scale System Quality Impr 48
Integrating Big “QI,” Little “qi,” and Individual “qi” .................... 49
Work Processes Integrate to Form a System ............................ 51
Understand the System to Manage Performance ........................ 52
Notes ............................................................. 53
Chapter 5 Remove Disruptions to Improve Flow:
Project Sequence for Modular Kaizen ................................. 55
The Value of Modular Kaizen at the Action Level ....................... 55
Modular Kaizen Using the DMAIC Model ............................. 58
Process Maps Provide Different Views of the System .................... 61
Documentation as Part of the Control Phase ............................ 67
Analyze System Disruption .......................................... 69
Priority—Process—Task—Action ..................................... 70
Anticipating the Impact of Change across the System 76
Conclusion ........................................................ 77
Notes ............................................................. 78
Chapter 6 The Tools of Modular Kaizen ................................ 79
Introduction ....................................................... 79
The Evolution of the House of Modular Kaizen ......................... 81
Notes 91
Chapter 7 A School of Fishbones Guides Quality Improvement .......... 93
Cause and Effect Diagram ........................................... 94
Force and Effect Chart ............................................... 95
Solution and Ef ......................................... 96
Success and Effect Diagram .......................................... 100
Notes ............................................................. 104
Chapter 8 Process and Outcome Measures in Modular Kaizen ............ 105
Measurement Activities Using the DMAIC Improvement Model .......... 106
Three Major Measurement Areas ..................................... 108
Matching Measures to the Process and Outcome ........................ 112
Develop the Measurement Plan ...................................... 112
Measure the Process to Ensure Continued Success ...................... 114
Notes 115
Part II Modular Kaizen Applications ............................ 117
Chapter 9 Automotive Manufacturing Application of Modular Kaizen .... 119
Understand and Define the Problem .................................. 119
Collect, Analyze, and Prioritize Data 127
Identify Possible Solutions ........................................... 127
Select the Best Solution .............................................. 131
Duffy.indb 6 10/24/13 10:33 AMTable of ConTenTs vii
Develop an Action Plan ............................................. 131
Implement and Document the Solution ................................ 132
Evaluate the Effectiveness of the Improvement (Control Plan) ............ 133
Notes ............................................................. 133
Chapter 10 Meeting Effectiveness Evaluation Project .................... 135
Introduction ....................................................... 135
Understand and Define the Problem/Opportunity ...................... 136
Collect, Analyze, and Prioritize Data .................................. 138
Identify Possible Solutions ........................................... 138
Select the Best Solution .............................................. 142
Implement and Document the Solution ................................ 143
Develop an Action Plan ............................................. 151
Evaluate the Effectiveness of the Improvement ......................... 155
Note .............................................................. 157
Chapter 11 A NASA Space Coast Kaizen Model 159
Introduction 159
Understand and Define the Problem/Opportunity ...................... 161
Collect, Analyze, and Prioritize Data .................................. 172
Identify Possible Solutions ........................................... 175
Select the Best Solutions 175
Develop an Implementation Plan ..................................... 178
Implement the Solution ............................................. 179
Evaluate the Effectiveness of the Improvement ......................... 180